Injection molding flow control apparatus and method

ABSTRACT

Injection molding apparatuses and methods wherein a valve pin is controllably driven upstream and downstream along an axis between a first closed position where the tip end of the valve pin obstructs the gate to prevent the injection fluid from flowing into the cavity, a full open position and one or more intermediate positions, 
     wherein the valve pin is drivable to be disposed or held in a selected intermediate position for a selected period of time during the course of an injection cycle where the tip end of the valve pin restricts flow of injection fluid through the gate to the mold cavity.

This application is a continuation of and claims the benefit of priorityto U.S. application Ser. No. 16/054,386 filed Aug. 3, 2018, which is acontinuation of and claims the benefit of priority to U.S. applicationSer. No. 15/432,175 filed Feb. 14, 2017, which is a continuation of andclaims the benefit of priority to U.S. application Ser. No. 14/930,692filed Nov. 3, 2015, which is a continuation of and claims the benefit ofpriority to U.S. application Ser. No. 13/569,464 filed Aug. 8, 2012. Thedisclosures of these applications are incorporated by reference in theirentirety as if fully set forth herein.

BACKGROUND

Injection molding systems have been developed having flow controlmechanisms (e.g., a controller) that control the movement and/or rate ofmovement of a valve pin over the course of an injection cycle to causethe pin to move to one or select positions and/or to control the rate ofmovement of the pin over the course of the injection cycle. In oneembodiment, the pin movement is controlled in order to raise or lowerthe rate of flow of fluid material to correspond to a predeterminedprofile of fluid flow rates for the injection cycle. A sensor istypically provided that senses a condition of the fluid material or ofthe apparatus (such as pin position) and sends a signal indicative ofthe sensed condition to a program contained in a controller that usesthe signal as a variable input to control movement of the valve pin inaccordance with the predetermined profile.

SUMMARY OF THE INVENTION

The present invention relates to the storage and transmission of recipedata (process parameters) for the molding of articles in an injectionmolding machine. A controller includes a flow control microcontroller(MCU) that receives recipe data from a recipe storage microcontroller(MCU) mounted to a mold of an injection molding machine, the recipestorage MCU storing the recipe data defining process parameters for themolding of articles in the mold. The flow control MCU executesinstructions for controlling pin motions in the mold according to therecipe data. In one embodiment, a human operator interface is providedfor transmitting data to and/or from at least one of the recipe storageand flow control MCU's, allowing the operator to monitor, modify and/orcontrol the process parameters during a molding cycle and/or to create amodified or new recipe for subsequent storage on the recipe storage MCU.

In accordance with one embodiment of the invention, a system is providedcomprising a recipe storage microcontroller (MCU) mounted to a mold ofan injection molding machine and storing recipe data defining processparameters for molding articles in the mold, wherein the recipe dataincludes one or more profiles of data representative of events orconditions during or over corresponding injection cycles that controloperation of one or more valve pins to control the rate of flow ofinjection material to the mold over the course of the injection cycles,

a flow controller, including a flow control microcontroller (MCU),remote from the mold and operative to receive the recipe data andexecute instructions for controlling valve pin motion(s) according tothe recipe data; and

a human operator interface remote from the mold and either remote-fromor local-to the controller for transmitting recipe data to and/or fromat least one of the recipe storage and flow control MCUs;

wherein each MCU is a single chip microcontroller.

In one embodiment, the system includes a first communication channelbetween the human operator interface and controller, and a secondcommunication channel between the recipe storage MCU and the controller.

In another embodiment, the flow control MCU is mounted on a circuitboard mounted on the injection molding machine.

In another embodiment, the recipe storage MCU is mounted on a circuitboard mounted on the mold.

In another embodiment, the system includes a display.

In another embodiment, the display is mounted on the injection moldingmachine and includes one or more parameters relating to valve pinmotion(s).

In another embodiment, the recipe storage MCU is mounted in a junctionbox and the junction box transmits signals between the mold and the flowcontrol MCU for controlling the valve pin motion(s).

In another embodiment, the profile comprises a profile of one or more ofvalve pin position, pressure of an injection material, temperature of aninjection material or position of another operational component of thesystem.

In another embodiment, the human operator interface is a voice activatedinterface.

In another embodiment, the human operator interface is a wirelessinterface.

In another embodiment, the human operator interface is a wiredinterface.

In another embodiment, the flow control MCU controls the motions of aplurality of valve pins.

In another embodiment, the system includes a plurality of flow controlMCUs each controlling a corresponding one of a plurality of pins.

In another embodiment, the flow control MCU is mounted on a hydraulicpower unit.

In one embodiment, at least one flow control MCU, receives, displaysand/or records a signal from an electronic mold counting sensor forcorrelating detected pin motion data to the recipe data during a givenmolding cycle.

In accordance with one embodiment of the invention, a system is providedcomprising a recipe storage microcontroller (MCU) storing recipe datadefining process parameters for molding articles in a mold, and a flowcontroller including a flow control MCU, both the recipe storage MCU andthe flow control MCU being mounted to the mold;

the recipe data including one or more profiles of data representative ofone or more events or conditions during or over corresponding injectioncycles that control operation of one or more valve pins to control therate of flow of injection material to the mold over the course of theinjection cycles;the flow control MCU being operative to receive the recipe data andexecute instructions for controlling valve pin motion(s) in the moldaccording to the recipe data; anda human operator interface remote from the mold for transmitting recipedata to and/or from at least one of the MCUs;wherein each MCU is a single chip data microcontroller.

In one embodiment, the recipe data includes a rate of pin movement.

In another embodiment, the recipe data includes a pressure profile for amolding cycle.

In another embodiment, the flow control MCU generates signals for anelectric motor for controlling one or more of pin position and rate ofpin movement.

In accordance with one embodiment of the invention, a method is providedcomprising electronically transmitting a recipe of data from a humanoperator interface to a recipe storage system mounted on a mold of aninjection molding machine, the recipe storage system including a recipestorage microcontroller (MCU) for storing the recipe, wherein the recipedata includes one or more profiles of data representative of one or moreevents or conditions during or over corresponding injection cycles thatcontrol operation of one or more valve pins to control the rate of flowof injection material to the mold over the course of the injectioncycles;

a controller, remote from the mold, including a flow control MCUexecuting computer instructions to control the valve pin motion(s)during a process of molding part(s) in the mold in accordance with therecipe,

electronically transmitting feedback concerning the molding processand/or the molded part(s) to the operator interface; and

electronically transmitting a modified recipe from the operatorinterface to the recipe storage system for a subsequent process ofmolding parts.

In accordance with one embodiment of the invention, a method is providedcomprising transmitting, from a mold MCU mounted on a mold of aninjection molding machine to a flow control MCU remote from the mold, arecipe of data defining process parameters for molding articles in themold, wherein the recipe data includes one or more profiles of datarepresentative of one or more events or conditions during or overcorresponding injection cycles that control operation of one or morevalve pins to control the rate of flow of injection material to the moldover the course of the injection cycles; transmitting signals from theflow control MCU to an actuating system that controls the molding ofarticles in the mold according to the recipe;

operating the actuating system according to the signals to producearticles in the mold.

In another embodiment, the method includes transmitting feedbacksignals, from the actuating system, the mold and/or a manifold mountedto the machine, to the flow control MCU concerning the molding processand/or the molded parts.

In another embodiment, the method includes receiving, at the mold MCU, amodified recipe based on the feedback signals.

In another embodiment, the method includes transmitting, from the moldMCU to the flow control MCU, the modified recipe.

In one embodiment, the method includes transmitting signals from theflow control MCU to the actuating system to control the molding ofarticles in the mold according to the modified recipe.

In one embodiment, the method includes removing the mold from themachine and inserting a new mold, the new mold including as the recipe anew mold recipe stored on the new mold MCU prior to the inserting step.

In one embodiment, the method includes transmitting the new mold recipefrom the new mold MCU to the flow control MCU.

In one embodiment, the method includes transmitting signals from theflow control MCU to the actuating system to control the molding ofarticles in the mold according to the new mold recipe.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be betterunderstood by referring to the following description in conjunction withthe accompanying drawings in which:

FIG. 1 is a schematic of one embodiment of the invention utilizingmicrocontrollers (MCUs) for monitoring and/or controlling an injectionmolding process, the system including a recipe MCU located at the moldand a flow control MCU preferably remote from (optionally local to) themold, and various human operator interfaces remote from the mold formonitoring and/or providing input to the MCUs with regard to theinjection molding process;

FIG. 2 is a flow chart illustrating one method embodiment of theinvention;

FIG. 3 is a flow chart illustrating another method embodiment of theinvention;

FIG. 4 is a flow chart illustrating another method embodiment of theinvention;

FIG. 5 is a flow chart illustrating another method embodiment of theinvention;

FIG. 6 is a schematic of one embodiment of an injection moldingapparatus utilizing the invention during an injection molding cycle,namely a recipe (of process parameters) stored on a recipe storagesystem mounted in a mold is transmitted to and executed by a controller,the molding apparatus including a pair of sequential gates with a firstgate entering a center portion of a mold cavity having been opened andnow closed such that a first shot of fluid material has entered thecavity and traveled past the positions of a pair of second sequentialgates (one at each end of the mold cavity), each second gate being openwith its valve pin having traveled along an upstream restricted flowpath RP allowing a second sequential shot of fluid material to flow intoand merge with the first shot of material within the cavity;

FIGS. 6A-6E are schematic cross-sectional close-up views of the centerand one of the lateral gates of the FIG. 6 apparatus showing variousstages of the progress of injection;

FIG. 7 is a schematic of one embodiment of a hydraulically actuatedvalve pin in which at least one port of an actuator is connected to aflow restrictor so as to restrict the flow of hydraulic drive fluid andslow the opening of the valve pin by a selected lessening of pin openingvelocity by use of a controller interconnected to the flow restrictor,the controller enabling the user to select a percentage of predeterminedfull open position velocity that the hydraulic drive supply to theactuator normally operates at full open velocity drive fluid pressure;

FIGS. 7A, 7B are schematic cross-sectional views of the hydraulic valvesand restrictors used in the system of FIG. 6;

FIGS. 8A, 8B show various embodiments of piston sensors that can be usedin a variety of implementations of the invention, the sensors shown inthese figures being mounted so as to measure the position of the pistoncomponent of the actuator which is indicative of the position of thevalve pin relative to the gate;

FIGS. 8C, 8D show embodiments using limit switches that detect andsignal specific positions of the actuator that can be used to determinevelocity, position and switchover to higher openness of valve restrictorand/or upstream velocity of travel of the actuator and valve pin;

FIGS. 9A-9D are a series of graphs representing actual pressure (versustarget pressure) measured in four injection nozzles coupled to amanifold, such as in the apparatus of FIG. 6; and

FIG. 10 shows an interactive screen display of a user interface, such asthat shown in FIG. 1, which screen is used to display, create, edit andstore target profiles.

DETAILED DESCRIPTION

Various embodiments of the present invention are now described withreference to the drawings. In the following description, for purposes ofexplanation, numerous specific details are set forth in order to providea thorough understanding of one or more implementations of the presentinvention. It will be evident, however, that the present invention maybe practiced without these specific details. In other instances,well-known structures and devices are shown in block diagram form inorder to facilitate describing the present invention.

As used in this application with regard to various monitoring andcontrol systems, the terms “component” and “system” are intended torefer to a computer-related entity, either hardware, a combination ofhardware and software, software, or software in execution. For example,a component may be, but is not limited to being, a process running on aprocessor, a processor, an object, an executable, a thread of execution,a program, and/or a computer. By way of illustration, both anapplication running on a server and the server can be a component. Oneor more components may reside within a process and/or thread ofexecution and a component may be localized on one computer and/ordistributed between two or more computers.

The present invention may also be illustrated as a flow chart of aprocess of the invention. While, for the purposes of simplicity ofexplanation, the one or more methodologies shown in the form of a flowchart are described as a series of acts, it is to be understood andappreciated that the present invention is not limited by the order ofacts, as some acts may, in accordance with the present invention, occurin a different order and/or concurrent with other acts from that shownand described herein. For example, those skilled in the art willunderstand and appreciate that a methodology could alternatively berepresented as a series of interrelated states or events, such as in astate diagram. Moreover, not all illustrated acts may be required toimplement a methodology in accordance with the present invention.

In various embodiments of the invention disclosed herein, the term“data” is used. Data means any sequence of symbols (typically denoted“0” and “1”) that can be input into a computer, stored and processedthere, or transmitted to another computer. As used herein, data includesmetadata, a description of other data. Data written to storage may bedata elements of the same size, or data elements of variable sizes. Someexamples of data include information, program code, program state,program data, other data, and the like.

As used herein, computer storage media includes both volatile andnon-volatile, removable and non-removable media for storage ofinformation such as computer-readable instructions, data structures,program modules, or other data. Computer storage media includes RAM,ROM, EEPROM, FLASH memory or other memory technology, CD-ROM, digitalversatile disc (DVDs) or other optical disk storage, magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other medium which can be used to store desired information andwhich can be accessed by the computer.

The methods described below may be implemented in a suitable computingand storage environment, e.g., in the context of computer-executableinstructions that may run on one or more processors, microcontrollers orother computers. In a distributed computing environment (for example)certain tasks are performed by remote processing devices that are linkedthrough a communications network and program modules may be located inboth local and remote memory storage devices. The communications networkmay include a global area network, e.g., the Internet, a local areanetwork, a wide area network or other computer network. It will beappreciated that the network connections described herein are exemplaryand other means of establishing communications between the computers maybe used.

A computer may include one or more processors and memory, e.g., aprocessing unit, a system memory, and system bus, wherein the system buscouples the system components including, but not limited to, the systemmemory and the processing unit. A computer may further include diskdrives and interfaces to external components. A variety ofcomputer-readable media can be accessed by the computer and includesboth volatile and nonvolatile media, removable and nonremovable media. Acomputer may include various user interface devices including a displayscreen, touch screen, keyboard or mouse.

A microcontroller (MCU) is used in the present invention to control someor all of the functions of an electronic device or system. An MCU is asmall self-contained computer chip, essentially comprising a smallcomputer on a single integrated circuit and including a microprocessor,memory, and I/O on a single chip. The chip may be programmed for selectfunctions, the program code being stored on Flash, EPROM or othernon-violate memory. An MCU is used in each of a recipe storage system, aflow control system, and a user interface system in the embodimentdescribed below. The MCU may be embedded in a printed circuit board(PCB), e.g., within the main PCB of the controller, a PCB within astorage device (in a junction box) and/or a PCB within an input device(such as a voice input interface). In contrast, PLC's (programmablelogical controllers) are costly and not as effective (too slow and/oroffer limited functionality).

Flow Control Apparatus and Method

FIG. 1 is a schematic diagram of a flow control apparatus and methodaccording to one embodiment of the invention. In the disclosedembodiment, a recipe storage MCU and flow control MCU replace the priorknown controller, and preferably communicate with a new operatorinterface. It is to be understood that the new flow control apparatusand method can be used with various injection molding machines andmolding processes known to the skilled person.

In the advanced flow control system 10 of the present embodiment, acontroller 8 includes a flow control microcontroller (MCU) 9, alsoreferred to as the main MCU. The main MCU is operative to communicate(over wired or wireless media 29) with one or more types of userinterfaces 21 including for example a voice activated interface 23, amobile (wi-fi) interface 25, and a wired interface 27. A user (humanoperator) 31 can input to the interface 21 various process parameters,such as inputs to a recipe for controlling various types of actuatorsused in the molding process. The inputs will be transmitted from theuser interface to the main flow control MCU. The flow control MCU inturn communicates (over wired or wireless media 51) with a remote recipestorage MCU 16 mounted on a mold 40 of an injection molding apparatus 41(also referred as to an injection molding machine). The mold includesone or more pins (see FIG. 6) each driven by an actuator 45 for openingand closing one or more respective mold cavities (see FIG. 6). Theactuator may be any type of known actuator, including electrical,hydraulic, or pneumatic actuators. The actuator drives a pin for openingand closing a gate (an opening into the mold cavity), and the movementof the pin may be monitored by one or more sensors or signals on/fromthe mold 40 or machine 41 for determining one or more process parameterssuch as pin position, pin velocity, or melt pressure in the cavity or ina fluid channel upstream of the cavity (e.g., manifold), or temperaturein the cavity or in a fluid channel upstream of the cavity, or the moldcycle count. The recipe, for a respective mold, is stored in the recipestorage MCU 16 which is mounted on the mold 40, and the recipe iselectronically transmitted from the recipe MCU 16 to the main MCU 9,remote from the mold, the latter of which implements computerinstructions for controlling various parameters related to the moldingprocess of the respective mold in accordance with the recipe.

In one example, the flow control (main) MCU 9 will automatically obtainor receive the recipe of process parameters (e.g., set-up information)from the remote recipe MCU 16 which is located on the mold. This allowsfor uninterrupted mold changes, namely the mold and its associatedrecipe will be read automatically by the flow control MCU 9, withoutrequiring programming of the flow control MCU. The transmitted recipedata can be implemented by executing the flow control computerinstructions stored on the flow control MCU 9. For example, the flowcontrol MCU can be used to control the velocity of the pin(s), maintainthe melt pressure at a desired melt pressure profile, and/or sequencethe pin(s) in a mold using various other inputs.

Furthermore, the flow control (main) MCU 9 receives as input(s) from themold 40 and/or machine 41 one or more electronic signals (digital oranalog), over communication channels 51, indicative of the moldingprocess, thus providing a feedback loop for one or more processparameters, e.g., for pressure control based on melt pressure and/orcavity pressure. This feedback can be provided or displayed to anoperator 31, allowing the operator to input changes to the recipe, andthe modified recipe can then be executed by the main MCU (as the newcurrent recipe).

In one embodiment, the recipe storage MCU 16 is mounted on an electricaljunction box (a container for electrical connections) which allows forcommunications between the mold 40 and the flow control MCU 9 in orderto retrieve and store recipes on the mold MCU 16. In addition tocommunicating the recipe data, the flow control MCU can interact (e.g.,via the junction box) with various optional sensors and signals on/fromthe mold and machine, such as position sensors, melt pressure sensors,cavity pressure sensors, temperature sensors, screw position and otherinjection molding machine signals to control the actuation of each pinin the mold, or the mold cycle count. FIG. 1 shows various signals,including recipe 52, position 53, melt pressure 54 and cavity pressure55, being electronically transmitted from the mold machine to the remotemain MCU 9, e.g., via wired or wireless communication channel(s).

As previously described, the user interface 21 enables a user 31 (humanoperator) to observe the tracking of the actual process parameters,versus the target (desired) process parameters, during the injectioncycle in real time, or after the cycle is complete. In one example, theinterface 21 includes an associated display 22 for tracking suchparameters. One type of display is a simple indicator panel (similar topanel 61 shown in communication with the controller 8) that tells theoperator whether the valve pin is open or closed. In this example, thecontrol system can transmit discrete signals indicating whether thevalve pin is closed or opened.

In another example, a display (such as display 71) is provided thatenables continuous position monitoring of the pin, by the user. In thisexample, the control system 8 transmits a signal to drive a displayshowing (e.g., in a graph of position versus time) the position of thevalve pin throughout the injection cycle.

The display(s) can be either local or remote with respect to the flowcontrol MCU, the user interface, and/or the mold. In one example, thepin open/closed indicator panel 61 is mounted on the injection moldingmachine 41. In another example, the graphical display 71 (of pinposition versus time) is provided on the user interface 21, such as on adisplay screen of a mobile telephone, smartphone, tablet or othercomputer device.

In one embodiment, the user interface 21 is a voice activated interface23 and includes a voice interpreter MCU 23 a. Such an interface mayutilize any of various readily available components, such as a voicerecognition chip. As the operator will typically have fairly specificand a limited range of inputs (commands), any of various commerciallyavailable voice recognition software can be used. For example, RSC-364is a single chip that combines the flexibility of a microcontroller withadvanced speech technology, including high-quality speech recognition,speech and music synthesis, speaker verification, and voice record andplayback. A product can use one or all of the RSC-364 features in asingle application. See http://www.sensoryinc.com/.

In another embodiment, the operator interface 21 is a mobile interface25, such as a WIFI interface, that can be accessed via a local wirelesshot spot. The wireless device can be any of various mobile laptops,tablets, smartphones, or other forms of computers, that can runapplications and/or a browser. In one example, a WIFI MCU 25 a receivesinput via the mobile device from the human operator 31 and communicatesparameters/commands to the flow control MCU 9. This would enable theoperator to travel around an injection molding facility or plant, whileinputting commands. Further, assuming the mobile device includes adisplay screen providing process feedback on the existing profile data,the operator can then generate and transmit changes to the recipe fromthe user interface to the mold MCU 16 (either directly or via the mainMCU 9). The modified recipe can then be stored at the mold MCU 16 as the(new) current recipe.

In a further alternative, the user interface 21 is a hardwired interface27 (including e.g., display 22 and pendent MCU 27 a as shown in FIG. 1),such as a desktop computer or computer device with an input keyboard orgraphical user interface. The one or more interfaces 23, 25, 27 can beconnected to the main MCU 9 of controller 8 via wired or wirelesscommunication channels 29.

Flow Control Method

FIG. 2 illustrates one method embodiment 200 of the invention. In step210, the current recipe stored on a recipe storage MCU located on themold, is transmitted to the remote main MCU. In the next step 212, themain MCU executes computer instructions to control the injection moldingprocess in accordance with the current recipe.

Another method embodiment 300 of the invention is illustrated in FIG. 3.In a first step 310, the current recipe is transmitted from the recipestorage MCU located on the mold to the remote main MCU and stored as the(new) current recipe. In a next step 312, the current recipe isdisplayed. In step 314, a human operator (viewing the display)determines whether changes are required to the current recipe. Ifchanges are required, then in step 316 the operator inputs changes tothe current recipe via a remote human operator interface, creating amodified recipe. Next, at step 318, the modified recipe is transmittedto the main MCU and/or recipe storage MCU and stored as the (new)current recipe. Then the method proceeds to step 320, where the main MCUexecutes computer instructions to control the injection molding processin accordance with the current (modified) recipe. Alternatively, if nochanges are required to the current recipe (at step 314), then themethod proceeds immediately to step 320 to execute the computerinstructions in accordance with the current (unmodified) recipe.

FIG. 4 illustrates another method embodiment 400 of the invention. In afirst step 410, the current recipe is transmitted from the recipestorage MCU located on the mold to the remote main MCU. In the next step412, the main MCU executes computer instructions to control theinjection molding process in accordance with the recipe. In the nextstep 414, process feedback is displayed, for example process parametersand/or molded part parameters from which the human operator candetermine whether to make changes to the recipe. In the next step 416,the human operator determines whether changes to the current recipe arerequired. If so, in the next step 418 the operator inputs changes to thecurrent recipe via a remote operator interface creating a modifiedrecipe. In the next step 420, the modified recipe is transmitted to themain MCU and/or the recipe storage MCU. In the next step 422, the mainMCU executes computer instructions to control the injection moldingprocess in accordance with the new current (modified) recipe.Alternatively, if no changes are required (at step 414), then the methodproceeds directly to step 422 to execute the computer instructions inaccordance with the current (unmodified) recipe. In an optional furtherfeedback loop, during or after step 422 the process returns to step 414to display process feedback, wherein the operator can then determine atstep 416 whether to further modify the current (or previously modified)recipe.

FIG. 5 illustrates a further method embodiment 500 of the invention. Ina first step 510, a mold is added or changed having a recipe storage MCUlocated on the mold storing the current recipe. In a next step 512, thecurrent recipe is transmitted from the recipe MCU located on the mold tothe remote main MCU. In a next step 514, the main MCU executes computerinstructions to control the injection molding process in accordance withthe current recipe. Thus, the method illustrated in FIG. 5 would allow amold operator, such as a night-shift operator, to change the moldwithout having to input which recipe to run. The control system (e.g.,of FIG. 1) will automatically identify the mold and run the currentrecipe stored on the mold without any human operator input required.

Injection Molding Apparatus and Method

FIG. 6 shows an injection molding system 1000, including a controller1016 (with a flow control MCU 9 as per FIG. 1) and a recipe storagesystem 1010 (with a recipe storage MCU 16 as per FIG. 1), the latter ofwhich is mounted on a mold 1002 according to one embodiment of theinvention. In this example, three gates feed a mold cavity as specifiedby a recipe of process parameters stored on the mold storage device 1010and transmitted via communication channel 1009 to the main MCU incontroller 1016 for execution.

A central nozzle 1022 is shown in FIG. 6 feeding molten material from aninjection molding machine 1001 through a main inlet 1018 to adistribution channel 1019 of a manifold 1039. The distribution channelcommonly feeds three separate nozzles 1020, 1022, 1024 which allcommonly feed into a common cavity 1030 of a mold 1002 to make onemolded part. A central nozzle 1022 is controlled by actuator 1940 andarranged so as to feed into cavity 1030 at an entrance point or gatethat is disposed at about the center 1032 of the cavity. As shown, apair of lateral nozzles 1020, 1024 feed into the mold cavity 1030 atgate locations that are distal 1034, 1036 to the center gate feedposition 1032.

As shown in FIGS. 6 and 6A-6E, the injection cycle is a cascade processwhere injection is effected in a sequence from the center nozzle 1022first and at a later predetermined time from the lateral nozzles 1020,1024. As shown in FIG. 6A the injection cycle is started by firstopening the pin 1040 of the center nozzle 1022 and allowing the fluidmaterial M (typically polymer or plastic material) to flow up to aposition in the cavity just before 1100 b, the distally disposedentrance into the cavity of the lateral nozzle 1024. Once the fluidmaterial has further travelled just past the entrance to nozzle 1024, atposition 1100 p, the center gate 1032 of the center nozzle 1022 istypically closed by pin 1040 as shown in FIG. 6B. The lateral gates1034, 1036 are then opened by upstream withdrawal of lateral nozzle pins1041, 1042 as shown in FIGS. 6B-6E. The rate of upstream withdrawal ortravel velocity of lateral pins 1041, 1042 is controlled as describedbelow.

In alternative embodiments, the center gate 1032 and associated actuator1940 and valve pin 1040 can remain open at, during and subsequent to thetimes that the lateral gates 1034, 1036 are opened such that fluidmaterial flows into cavity 1030 through both the center gate 1032 andone or both of the lateral gates 1034, 1036 simultaneously.

When the lateral gates 1034, 1036 are opened and fluid material NM isallowed to first enter the mold cavity into the stream M that has beeninjected from center nozzle 1022 past gates 1034, 1036, the two streamsNM and M mix with each other. If the velocity of the fluid material NMis too high, such as often occurs when the flow velocity of injectionfluid material through gates 1034, 1036 is at maximum, a visible line ordefect in the mixing of the two streams M and NM will appear in thefinal cooled molded product at the areas where gates 1034, 1036 injectinto the mold cavity. By injecting NM at a reduced flow rate for arelatively short period of time at the beginning when the gates 1034,1036 are first opened and following the time when NM first enters theflow stream M, the appearance of a visible line or defect in the finalmolded product can be reduced or eliminated.

The rate or velocity of upstream withdrawal of lateral pins 1041, 1042starting from the closed position is controlled via controller 1016(FIGS. 6 and 7) which controls the rate and direction of flow ofhydraulic fluid from a drive system 1700 to actuators 1940, 1941, 1942.A “controller,” as used generally herein, refers to electrical andelectronic control apparati that comprise a single box or multiple boxes(typically interconnected and communicating with each other) thatcontain(s) all of the separate electronic processing, memory andelectrical signal generating components that are necessary or desirablefor carrying out and constructing the methods, functions and apparatusesdescribed herein. Such electronic and electrical components may includeprograms, microprocessors, computers, PID controllers, voltageregulators, current regulators, circuit boards, motors, batteries andinstructions for controlling any variable element discussed herein suchas length of time, degree of electrical signal output and the like. Forexample a component of a controller, as that term is used herein,includes programs, controllers and the like that perform functions suchas monitoring, alerting and initiating an injection molding cycleincluding a control device that is used as a standalone device forperforming conventional functions such as signaling and instructing anindividual injection valve or a series of interdependent valves to startan injection, namely move an actuator and associated valve pin from agate closed to a gate open position. In addition, although fluid drivenactuators are employed in the disclosed embodiments, actuators poweredby an electric or electronic motor or drive source can alternatively beused as the actuator component. Another embodiment would have thecontroller dynamically control the movement of an actuator andassociated valve pin in order to meet target pressure profiles basedupon (closed loop) feedback received by the controller from the pressuresensor. Yet another embodiment would have the controller trigger theopening and/or closing of an actuator and associated valve pin basedupon a sensed pressure or temperature condition within the cavity.

As shown in FIGS. 7A-7B, a supply of hydraulic fluid 1014 is fed firstthrough a directional control valve 1750 mechanism that switches thehydraulic fluid flow to the actuator cylinders in either of twodirections: fluid out to withdraw the pin upstream, FIG. 7A, and fluidin to drive the pin downstream, FIG. 7B. At the beginning of aninjection cycle the gate of a lateral valve 1034, 1036 is closed and thehydraulic system is in the directional configuration of FIG. 7B. When acycle is started, the directional configuration of the directional valve1750 of the hydraulic system 1700 is switched by controller 1016 to theconfiguration of FIG. 7A. The hydraulic system includes a flowrestriction valve 1600 that can vary the rate of flow of hydraulic fluidto the actuator 1941 under the control of the controller 1016 to varythe rate of travel, upstream or downstream of the piston of the actuator1941 which in turn controls the direction and rate of travel of pin1041. Although not shown in FIGS. 7A, 7B, the hydraulic system 1700controls the direction and rate of travel of the pistons of actuators1950 and 1952 in a manner similar to the manner of control of actuator1951 via the connections shown in FIG. 6.

The user programs controller 1016 via data inputs on a user interface toinstruct the hydraulic system 1700 to drive pins 1041, 1042 at anupstream velocity of travel that is reduced relative to a maximumvelocity that the hydraulic system can drive the pins 1041, 1042 totravel. As described below, such reduced pin withdrawal rate or velocityis executed until a position sensor such as 1951, 1952 detects that anactuator 1941, 1942 or an associated valve pin (or another component),has reached a certain position such as the end point of a restrictedflow path RP. A typical amount of time over which the pins are withdrawnat a reduced velocity is between about 0.01 and 0.10 second, the entireinjection cycle time typically being between about 0.3 seconds and about3 seconds, more typically between about 0.5 seconds and about 1.5seconds.

FIG. 6 shows position sensors 1950, 1951, 1952 for sensing the positionof their respective actuator cylinders (1940, 1941, 1942) and theirassociated valve pins (1040, 1041, 1042) and feeding such positioninformation to controller 1016 for monitoring purposes. As shown, fluidmaterial 1018 is injected from an injection machine into a manifoldrunner 1019 and further downstream into the bores 1044, 1046 of thelateral nozzles 1024, 1022 and ultimately downstream through the gates1032, 1034, 1036. When the pins 1041, 1042 are withdrawn upstream to aposition where the tip end of the pins 1041, 1042 are in a fullyupstream open FO position such as shown in FIG. 6D, the rate of flow offluid material through the gates 1034, 1036 is at a maximum. Howeverwhen the pins 1041, 1042 are initially withdrawn beginning from theclosed gate position, FIG. 6A, to intermediate upstream positions, FIGS.6B, 6C, a gap 1154, 1156 that restricts the velocity of fluid materialflow is formed between the outer surfaces 1155 of the tip end of thepins 1044, 1046 and the inner surfaces 1254, of the gate areas of thenozzles 1024, 1020. The restricted flow gap 1154, 1156 remains smallenough to restrict and reduce the rate of flow of fluid material Mthrough gates 1034, 1036 to a rate that is less than maximum flowvelocity over a travel distance RP of the tip end of the pins 1041, 1042going from closed to upstream as shown in FIGS. 6, 6B, 6C, 6E.

The trace or visible lines that appear in the body of a part that isultimately formed within the cavity of the mold on cooling above can bereduced or eliminated by reducing or controlling the velocity of the pin1041, 1042 opening or upstream withdrawal from the gate closed positionto a selected intermediate upstream gate open position that ispreferably 75% or more of the length of RP. RP can be about 1-8 mm inlength and more typically about 2-6 mm and even more typically 2-4 mm inlength. As shown in FIG. 7 in such an embodiment, a control system orcontroller 1016 is programmed to control the sequence and/or the ratesof valve pin 1040, 1041, 1042 opening and/or closing.

The velocity of withdrawal of the valve pins 1041, 1042 is determined byregulation of the flow of hydraulic drive fluid that is pumped from asupply 1014 to the actuators 1941, 1942 through a flow restrictor valve1600, FIGS. 6-7. When the flow restrictor valve 1600 is completely open,namely 100% open, allowing maximum flow of the pressurized hydraulicfluid to the actuator cylinders, the valve pins 1041, 1042 are driven ata maximum upstream travel velocity. The degree of openness of the flowrestrictor valve is adjusted in response to sensing of position of asuitable component such as an actuator 1941, 1942 or associated valvepin to less than 100% open. Adjustment of the flow restrictor valve 1600to less than 100% open thus reduces the rate and volume flow ofpressurized hydraulic fluid to the actuator cylinders thus in turnreducing the velocity of upstream travel of the pins 1041, 1042 for theselected period of time. At the end of the travel or length of path RP,a position sensor signals the controller 1016, the controller 1016determines that the end has been reached and the valve 1600 is opened toa higher velocity, typically to its 100% open position to allow theactuator pistons and the valve pins 1041, 1042 to be driven at maximumupstream velocity in order to reduce the cycle time of the injectioncycle.

The valve 1600 typically comprises a restrictor valve that iscontrollably positionable anywhere between completely closed (0% open)and completely open (100% open). Adjustment of the position of therestrictor valve 1600 is typically accomplished via a source ofelectrical power that controllably drives an electromechanical mechanismthat causes the valve to rotate such as a rotating spool that reacts toa magnetic or electromagnetic field created by the electrical signaloutput of the controller 1016, namely an output of electrical energy,electrical power, voltage, current or amperage the degree or amount ofwhich can be readily and controllably varied by conventional electricaloutput devices. The electro-mechanism is controllably drivable to causethe valve 1600 to open or close to a degree of openness that isproportional to the amount or degree of electrical energy that is inputto drive the electro-mechanism. The velocity of upstream withdrawaltravel of the pins 1041, 1042 are in turn proportional to the degree ofopenness of the valve 1600.

FIGS. 8A-8D show various examples of position sensors, the mounting andoperation of which are described in U.S. Patent Publication No.2009/0061034, the disclosure of which is incorporated herein byreference. As shown the position sensor 800 of FIGS. 8A and 8B forexample can track and signal the position of the piston of an actuatorpiston 823 continuously along its entire path of travel from which dataa pin velocity can be continuously calculated over the length of RP viaa spring loaded follower 802 that is in constant engagement with flange804 during the course of travel of piston 823. Mechanism 800 constantlysends signals to controller 1016 in real time to report the position ofpin 1041 and its associated actuator. FIGS. 8C, 8D show alternativeembodiments using position switches that detect position at specificindividual positions of the actuator and its associated valve pin 1041.The FIG. 8C embodiment uses a single trip position switch 830 a withtrip mechanism 833 that physically engages with the piston surface 823 awhen the piston 823 reaches the position of the trip mechanism 833. TheFIG. 8D embodiment shows the use of two separate position switches 830a, 830 aa having sequentially spaced trips 833 aa and 833 aaa thatreport the difference in time or distance between each trip engagingsurface 823 a of the piston, the data from which can be used bycontroller 1016 to calculate velocity of the actuator based on the timeof travel of the actuator from tripping one switch 830 a and thentripping the next 830 aa. In each embodiment the position switch cansignal the controller 1016 when the valve pin 1041, 1042 has travelledto one or more selected intermediate upstream gate open positionsbetween GC (gate closed) and RP so that the velocity of the pin can beadjusted to the selected or predetermined velocities determined by theuser. As can be readily imagined other position sensor mechanisms can beused such as optical sensors, sensors that mechanically orelectronically detect the movement of the valve pin or actuator or themovement of another component of the apparatus that corresponds tomovement of the actuator or valve pin.

In alternative embodiments the controller can include a processor andinstructions that receive the pin position information and signals fromthe position sensor and calculate the real time velocity of the pin fromthe pin position data in real time at one or more times or positionsover the course of the pin travel through the RP path length and/orbeyond. Typically such calculations of velocity are continuousthroughout the cycle. In such an embodiment, the calculated pin velocityis constantly compared to a predetermined target profile of pinvelocities and the velocity of the pin is adjusted in real time by thecontroller 1016 to conform to the profile. In this embodiment, as in theprevious described embodiment, the pin is moved continuously upstream atall times between the gate closed position and all positions upstream ofthe gate closed position. Such control systems are described in greaterdetail in for example U.S. Patent Publication No. 2009/0061034, thedisclosure of which is incorporated herein by reference.

As discussed above, control over the velocity of pin movement in anembodiment where the pin is driven by a hydraulic or pneumatic actuatoris typically accomplished by controlling the degree of openness of thefluid restriction valve 1600, control over velocity and drive rate orposition of valve 1600 being the same functions in terms of theinstructions, processor design or computer software that carries outinstructing and implementing the velocity or drive rate adjustment tothe valve pin or actuator. Where the position sensing system senses theposition of the pin or other component multiple times throughout thecourse of the pin or other component movement, and real time velocitycan be calculated by the controller 1016, a program or instructions canbe alternatively used to receive a velocity data input by the user tothe controller 1016 as the variable to be stored and processed insteadof a predetermined voltage or current input Where an actuator thatcomprises an electric motor is used as the drive mechanism for movingthe valve pin 1041, 1042 instead of a fluid driven actuator, thecontroller 1016 can similarly be programmed to receive and processvelocity data input as a variable for controlling the velocity or rateof drive of the electric actuator.

User Interface and Target Profiles

FIG. 9 shows time versus pressure graphs (1235, 1237, 1239, 1241) of thepressure detected by four pressure transducers associated with fournozzles mounted in a manifold block. The four nozzles are substantiallysimilar to the nozzles shown in FIG. 6 and include pressure transducerscoupled to the controller 1016.

The graphs of FIGS. 9A-9D are generated on a user interface (e.g., 21,71 of FIG. 1), so that a user can observe the tracking of the actualpressure versus the target pressure during the injection cycle in realtime, or after the cycle is complete. The four different graphs of FIG.9 show four independent target pressure profiles (“desired”) emulated bythe four individual nozzles. Different target profiles are desirable touniformly fill different sized individual cavities associated with eachnozzle, or to uniformly fill different sized sections of a singlecavity. Graphs such as these can be generated with respect to any of theprevious embodiments described herein.

The valve pin associated with graph 1235 is opened sequentially at 0.5seconds after the valves associated with the other three graphs (1237,1239 and 1241) were opened at 0.00 seconds. At approximately 6.25seconds, at the end of the injection cycle, all four valve pins are backin the closed position. During injection (for example, 0.00 to 1.0seconds in FIG. 9B) and pack (for example, 1.0 to 6.25 seconds in FIG.9B) portions of the graphs, each valve pin is controlled to a pluralityof positions to alter the pressure sensed by the pressure transducerassociated therewith to track the target pressure.

Through the user interface, target profiles can be designed, and changescan be made to any of the target profiles using standard (e.g.,windows-based) editing techniques. The profiles are then used bycontroller 1016 to control the position of the valve pin. For example,FIG. 10 shows an example of a profile creation and editing screen 1300generated on a user interface.

Screen 1300 is generated by a windows-based application performed on theuser interface, e.g., any of the user interfaces 21 shown in FIG. 1.Alternatively, this screen display could be generated on an interfaceassociated with the controller (e.g., display 71 associated withcontroller 8 in FIG. 1). Interactive screen 1300 provides a user withthe ability to create a new target profile or edit an existing targetprofile for any given nozzle and cavity associated therewith.

A profile 1310 includes (x, y) data pairs, corresponding to time values1320 and pressure values 1330 which represent the desired pressuresensed by the pressure transducer for the particular nozzle beingprofiled. The screen shown in FIG. 10 is shown in a “basic” mode inwhich a limited group of parameters are entered to generate a profile.For example, in the foregoing embodiment, the “basic” mode permits auser to input start time displayed at 1340, maximum fill pressuredisplayed at 1350 (also known as injection pressure), the start of packtime displayed at 1360, the pack pressure displayed at 1370, and thetotal cycle time displayed at 1380.

The screen also allows the user to select the particular valve pin theyare controlling displayed at 1390, and name the part being moldeddisplayed at 1400. Each of these parameters can be adjustedindependently using standard windows-based editing techniques such asusing a cursor to actuate up/down arrows 1410, or by simply typing invalues on a keyboard. As these parameters are entered and modified, theprofile will be displayed on a graph 1420 according to the parametersselected at that time.

By clicking on a pull-down menu arrow 1391, the user can selectdifferent nozzle valves in order to create, view or edit a profile forthe selected nozzle valve and cavity associated therewith. Also, a partname 1400 can be entered and displayed for each selected nozzle valve.

The newly edited profile can be saved in computer memory individually,or saved as a group of profiles for a group of nozzles that inject intoa particular single or multi-cavity mold. The term “recipe” is used todescribe one or more of profiles for a particular mold and the name ofthe particular recipe is displayed at 1430 on the screen icon.

To create a new profile or edit an existing profile, first the userselects a particular nozzle valve of the group of valves for theparticular recipe group being profiled. The valve selection is displayedat 1390. The user inputs an alpha/numeric name to be associated with theprofile being created, for family tool molds this may be called a partname displayed at 1400. The user then inputs a time displayed at 1340 tospecify when injection starts. A delay can be with particular valve pinsto sequence the opening of the valve pins and the injection of meltmaterial into different gates of a mold.

The user then inputs the fill (injection) pressure displayed at 1350. Inthe basic mode, the ramp from zero pressure to max fill pressure is afixed time, for example, 0.3 seconds. The user next inputs the startpack time to indicate when the pack phase of the injection cycle starts.The ramp from the filling phase to the packing phase is also fixed timein the basic mode, for example, 0.3 seconds.

The final parameter is the cycle time which is displayed at 1380 inwhich the user specifies when the pack phase (and the injection cycle)ends. The ramp from the pack phase to zero pressure may be instantaneouswhen a valve pin is used to close the gate, or slower in a thermal gatedue to the residual pressure in the cavity which will decay to zeropressure once the part solidifies in the mold cavity.

User input buttons 1415 through 1455 are used to save and load targetprofiles. Button 1415 permits the user to close the screen. When thisbutton is clicked, the current group of profiles will take effect forthe recipe being profiled. Cancel button 1425 is used to ignore currentprofile changes and revert back to the original profiles and close thescreen. Read Trace button 1435 is used to load an existing and savedtarget profile from memory. The profiles can be stored in memorycontained in one or more of the operator interface 21, the main MCU 9,and the recipe storage MCU 16. Save trace button 1440 is used to savethe current profile. Read group button 1445 is used to load an existingrecipe group. Save group button 1450 is used to save the current groupof target profiles for a group of nozzle valve pins. The process tuningbutton 1455 allows the user to change the settings (for example, thegains) for a particular nozzle valve in a control zone. Also displayedis a pressure range 1465 for the injection molding application.

While specific embodiments of the present invention have been shown anddescribed, it will be apparent that many modifications can be madethereto without departing from the scope of the invention. For example,in one embodiment the controller is mounted on a hydraulic power unit.In one embodiment, the flow control MCU receives, displays and/orrecords a signal from an electronic mold counting sensor for correlatingdetected pin motion data to the recipe data for a given molding cycle.In one embodiment, the system includes a plurality of flow control MCU'seach controlling a corresponding one of a plurality of pins. In oneembodiment, the flow control MCU transmits signals to an electric motorfor controlling one or more of pin position and rate of pin movement. Inone embodiment, both the recipe MCU and the flow control MCU are mountedto the mold. In one embodiment, the controller is contained in aphysical box which is mounted to the injection machine and/or placednear the injection machine. In one embodiment, the controller associates(compares) the recipe data to data collected during one injection cycle.In one embodiment, each valve pin has its own profile per injectioncycle, and the recipe is a collection of such profiles for a pluralityof pins.

In one embodiment, a mold having no recipe or a non-approved (notcurrent or previously tested) recipe stored in the recipe storage MCU,is mounted to the machine. An operator can then create a recipe bytesting different inputs to the controller, e.g., adjusting the rate ofspeed and/or position of one or more pins. When the user is satisfiedwith the parts being produced in the mold or with data and/or signalsreceived from the mold (e.g., temperature and/or pressure), the operatorthen stores a copy of the newly created recipe by transmitting (director indirectly) the new recipe for storage on the recipe storage MCU. Themain MCU of the controller stores a local copy of the new recipe, andruns the recipe (executes instructions implementing the recipe) for themold. Then later, if this first mold is removed and a new mold ismounted to the machine, where the new mold has a proper recipe alreadystored on the new mold MCU, the controller can then immediately run thenew recipe for the new mold on the machine. If not, the operator canagain create a new recipe for the new mold, as previously described.

The recipe data typically comprises a profile of values of a conditionof the injected polymer material or a condition or position of aselected component of the injection molding apparatus that is specifiedto occur at each point in time over the course or duration of aninjection cycle when a part is produced in the mold cavity. Thus aprofile defines a set of conditions, events or positions to which theinjection material or the component of the apparatus is adjusted toattain over the course of a particular injection cycle. Typicalinjection material conditions that can be specified and controlled arepressure of the injection material at selected positions within a flowchannel of the manifold, within an injection nozzle or within the moldcavity. Typical conditions or positions of components of the apparatusthat can be controlled and comprise a profile are the position of thevalve pin, the position of the screw of the barrel of the injectionmolding machine and position of an actuator piston. Such profiles andrecipes are disclosed in detail in for example U.S. Pat. Nos. 6,464,909and 8,016,581 and 7,597,828, the disclosures of which are incorporatedby reference as if fully set forth herein.

Various other embodiments will be apparent to the skilled person.Accordingly, the invention is not limited by the foregoing embodiments.

The invention claimed is:
 1. A flow control system for implementing aninjection molding process in which one or more nozzles, during aninjection cycle, feed fluid material(s) into a cavity of a mold, eachnozzle having an associated valve pin, driven by an associated actuator,for opening and closing a respective gate into the cavity, and aposition sensor is associated with each valve pin for monitoring aplurality of actual pin positions with respect to the gate andgenerating a sensor output signal indicative of the plurality of actualpin positions as the valve pin moves between gate closed and gate openpositions, the flow control system comprising: a junction box coupledvia a wireless media for transmitting and receiving wirelesscommunications with each of: a controller that controls movement of eachvalve pin over the course of the injection cycle in accordance with aset of process parameters, the controller being in wirelesscommunication with the junction box; a mobile user interface, inwireless communication with the junction box, configured to receiveinput from a human operator in the form of process parameters andcommands relating to the injection molding process for wirelesstransmission to at least one of the junction box and the controller; theflow control system being configured to receive and process the sensoroutput signal from the associated position sensor to determine, from theplurality of actual pin positions, one or more actual processparameters; and a user display being configured to receive and displaythe plurality of actual pin positions and/or the one or more actualprocess parameters by which a human operator can track the moldingprocess in real time during the injection cycle; wherein one or more ofthe junction box and the controller are configured to process the sensoroutput signal to generate a control signal to control the pin position;and the mobile user interface is configured to receive operator inputfor adjusting the control signal to control the pin position.
 2. Thesystem of claim 1, wherein the user display is provided on the mobileuser interface.
 3. The system of claim 2, wherein the mobile userinterface comprises a WIFI interface.
 4. The system of claim 2, whereinthe mobile user interface comprises a mobile telephone, smartphone,tablet or other computer device.
 5. The system of claim 1, wherein theflow control system is configured to transmit, to the mobile userinterface, data indicative of the plurality of actual pin positionsand/or the one or more actual process parameters.
 6. The system of claim1, wherein the flow control system is configured to transmit, to themobile user interface, data comprising one or more of: pin positionstatus; pin opening and/or pin closing times; pin opening and/or pinclosing velocities; and continuous actual pin position data for agraphical display of the plurality of actual pin positions versus time.7. The system of claim 1, wherein the mobile user interface acceptsoperator input commands for one or more modes of operation includingcontinuous monitoring of the actual pin position, and discretedetermination of the actual pin position as opened or closed.
 8. Thesystem of claim 7, wherein the mobile user interface transmits theoperator input command to the controller.
 9. The system of claim 1,wherein the user display enables the operator to track the actualprocess parameters in real time during the injection cycle.
 10. Thesystem of claim 1, wherein the mobile user interface is configured toreceive operator input for designing or changing a target profile. 11.The system of claim 10, wherein the mobile user interface provides aninteractive screen to create a new target profile or edit an existingtarget profile for any nozzle or cavity associated therewith.
 12. Thesystem of claim 2, wherein the user display is provided by a mobileapplication running on the mobile user interface.
 13. The system ofclaim 2, wherein the user display comprises an interactive screen thatallows the operator to select a particular valve pin to be controlledand displayed.
 14. The system of claim 1, wherein the position sensorcomprises a Hall Effect sensor or a Hall Effect circuit including a HallEffect sensor and one or more of a power regulator, signal amplifier,current converter, and signal driver.
 15. The system of claim 14,wherein: the Hall Effect sensor generates a voltage output signal; thevoltage output signal is amplified and converted to a current outputsignal by the Hall Effect circuit; and the current output signal istransmitted as the sensor output signal from an output port of the HallEffect circuit to an input port of the junction box or the controller.16. A method of monitoring valve pin positioning in an injection moldingsystem having a cavity with one or more gates and one or moreactuator-driven valve pins each associated with a respective gate foropening and closing the respective gate, the method comprising, for eachof the respective actuator-driven valve pins: controlling, via a flowcontrol system that implements a set of process parameters forcontrolling a molding process in the cavity, an actuator that drives anassociated valve pin with respect to an associated gate of the cavityalong a travel path including a plurality of actual pin positionsbetween gate open and gate closed positions; detecting, via a positionsensor that monitors movement of an associated valve pin while the valvepin moves along the travel path between the gate closed position,closing the associated gate to the cavity, to the gate open position,allowing fluid material to flow through the gate and into the cavity,and transmitting as a position sensor output signal to the flow controlsystem a detected actual movement of the valve pin along the travel pathupon opening of the gate indicative of an actual pin opening velocityand an actual pin opening time; receiving the position sensor outputsignal and generating display data indicative of actual processparameters including the actual pin opening time and the actual pinopening velocity; and displaying, via a user display, the display dataenabling a human operator to track the actual process parameters in realtime during the injection cycle including the actual pin opening timeand the actual pin opening velocity; wherein the flow control systemincludes a junction box coupled via a wireless communication media fortransmitting and receiving wireless communications with each of thecontroller and a mobile user interface; and the method furthercomprising: receiving, by the mobile user interface, input from a humanoperator in the form of process parameters or commands relating to theinjection molding process for wireless transmission to at least one ofthe junction box and the controller; wherein the controlling stepincludes using the position sensor output signal to generate a controlsignal to control the pin position; and receiving, at the mobile userinterface, operator input for adjusting the control signal to controlthe pin position.
 17. The method of claim 16, wherein the methodcomprises displaying on the user display on the mobile user interface.18. The method of claim 17, wherein the method comprises transmittingand receiving wireless communications via a WIFI interface on the mobileuser interface.
 19. The method of claim 17, wherein the method comprisestransmitting and receiving wireless communications via a mobiletelephone, smartphone, tablet or other computer device as the mobileuser interface.
 20. The method of claim 16, wherein the displaying stepincludes generating as the display data continuous actual pin positiondata for a graphical display of the plurality of actual pin positionsversus time and transmitting the display data to the mobile userinterface.
 21. The method of claim 16, wherein the mobile user interfaceaccepts operator input commands for one or more modes of operationincluding continuous monitoring of the actual pin position, and discretedetermination of the actual pin position as opened or closed.
 22. Themethod of claim 21, wherein the mobile user interface transmits theoperator input command to the controller.
 23. The method of claim 16,wherein the user display displays the actual process parameters in realtime during the injection cycle.
 24. The method of claim 16, wherein themobile user interface receives operator input for designing or changinga target profile.
 25. The method of claim 24, wherein the mobile userinterface provides an interactive screen to create a new target profileor edit an existing target profile for any nozzle or cavity associatedtherewith.
 26. The method of claim 17, wherein the user display isprovided by a mobile application running on the mobile user interface.27. The method of claim 16, wherein the position sensor comprises one ormore Hall Effect sensors for an associated valve pin.
 28. Anon-transitory computer readable medium storing a flow controlapplication for monitoring flow control during an injection moldingprocess in which one or more nozzles, during an injection cycle, feedfluid material(s) into a cavity of a mold, each nozzle having anassociated valve pin, driven by an associated actuator, for opening andclosing a respective gate into the cavity, and a controller controlsmovement of the valve pins over the course of the injection cycle inaccordance with a set of process parameters, the flow controlapplication providing an interactive screen and a user display on amobile user interface and a wireless communication channel with at leastone of a junction box and a controller for monitoring flow controlduring the injection cycle, wherein the interactive screen enables anoperator to input process parameters or commands, via the wirelesscommunication channel, to one or more of the controller and the junctionbox for performing a method including steps of: monitoring, via aposition sensor associated with each valve pin, a plurality of actualpin positions with respect to the gate and generating a sensor outputsignal indicative of the plurality of actual pin positions as the valvepin moves between gate closed and gate open positions; processing, viathe controller, the sensor output signal from the associated positionsensor to determine, from the plurality of actual pin positions, one ormore actual process parameters; and displaying, on the user display, theplurality of actual pin positions and/or the one or more actual processparameters by which a human operator can track the molding process inreal time during the injection cycle; and using the position sensoroutput signal to generate a control signal to control the pin position;and receiving, at the mobile user interface, operator input foradjusting the control signal to control the pin position.
 29. The flowcontrol application for implementing the method of claim 28, wherein themethod comprises: receiving, at the mobile user interface, operatorinput for selecting one or more modes of operation including: continuousmonitoring of the actual pin position, discrete determination of theactual pin position as opened or closed, creating a new target profile,and editing an existing target profile for any nozzle or cavityassociated therewith; and transmitting, via the wireless communicationchannel, a command to the controller to implement the selected operatorinput.
 30. The flow control application for implementing the method ofclaim 28, wherein the method comprises transmitting and receivingwireless communications via a WIFI interface on the mobile userinterface.
 31. The flow control application for implementing the methodof claim 28, wherein the method comprises transmitting and receivingwireless communications via a mobile telephone, smartphone, tablet orother computer device as the mobile user interface.
 32. The flow controlapplication for implementing the method of claim 28, wherein theprocessing step includes generating as display data continuous actualpin position data for a graphical display of the plurality of actual pinpositions versus time and transmitting the display data to the mobileuser interface.